Conductive wire objects of the flat strip type and flat strip type cable assemblies.

Abstract

Invention details;

Description

Flat ribbon type conductive wire and flat ribbon type wiring harness Technical Field

[0001] The present invention relates to the technical field of electrical connection, and in particular to a flat-belt type conductive wire and a flat-belt type wiring harness. Background Art

[0002] A vehicle's power source and electrical devices require a wiring harness for electrical connection. Round wire is a commonly used solution by those skilled in the art. With the increasing development of new energy vehicles, the functionality of in-vehicle electrical appliances is increasing, shrinking the available wiring space. Furthermore, because the power of electrical appliances in new energy vehicles far exceeds that of traditional fuel-powered vehicles, the increased current carrying capacity of the wiring harness, resulting in larger wire diameters and, consequently, increased electromagnetic interference, is becoming increasingly prominent. Therefore, finding a solution that can address the shrinking wiring space within a vehicle while also addressing the electromagnetic interference generated by the wiring harness itself has become a pressing technical challenge for those skilled in the art.

[0003] Summary of the Invention

[0004] The purpose of the present invention is to provide a flat-belt conductive wire and a flat-belt wire harness that can not only meet the increasingly smaller wiring space in the vehicle, but also solve the electromagnetic interference generated by the wire harness itself. The flat-belt wire harness can be arranged in a manner that fits the vehicle body and can be formed according to the shape of the vehicle body; according to the principle of skin effect, under the same current carrying capacity, the cross-sectional area of ​​the flat-belt conductive wire is smaller than the cross-sectional area of ​​the round wire, so the flat-belt conductive wire can reduce its wiring space used in the vehicle. At the same time, the present invention creatively provides a shielding layer outside the insulating layer of the flat-belt conductive wire, which can effectively solve the problem of electromagnetic interference to surrounding electrical appliances caused by the flat-belt conductive wire when it is powered on. Therefore, the technical solution of the present invention can, to a certain extent, solve the problem of insufficient wiring space and electromagnetic interference in automobiles, especially new energy vehicles.

[0005] The present invention provides a flat-belt conductive wire, comprising: a conductive core, an insulating layer and a shielding layer; the insulating layer wraps the conductive core, and the shielding layer is arranged outside the insulating layer.

[0006] By setting a shielding layer, the flat-belt conductive wire has good electromagnetic shielding function, strong anti-electromagnetic interference ability, and low installation space requirements. It can be widely used in occasions with high requirements for signal transmission stability. At the same time, it can avoid the problems of large space occupation and high cost caused by the use of large square shielded wires, and improve the space requirements of the entire vehicle for wiring harness layout.

[0007] Furthermore, the flat-belt conductive wire body further comprises a protective layer, the protective layer wrapping the shielding layer. Furthermore, the shielding layer comprises a shielding tape, the shielding tape being wrapped around the outside of the insulating layer.

[0008] The shielding layer is wrapped around the outside of the insulation layer in a winding manner using a shielding tape. This arrangement makes the shielding layer easy to process.

[0009] As an optional solution, the shielding tape is spirally wound on the insulating layer with a set overlapping width.

[0010] The shielding tape is spirally wound around the insulating layer with a set overlapping width, i.e., the shielding tape is tightly wound around the insulating layer. Specifically, during the winding process, a portion of the subsequent shielding tape overlaps the previous shielding tape, and there is an overlap between the subsequent and previous shielding tapes. The width of the overlapping portion is the overlap width. This winding method is simple and easy to operate and process, and can more completely wrap the insulating layer and conductive core, eliminating exposed areas and achieving a better shielding effect. As an alternative, the shielding tape can be multiple shielding tapes alternately wound around the insulating layer. Specifically, the width of the overlapping and intersecting portions of the shielding tape is the overlap width.

[0011] Furthermore, the set overlapping width is 1%-95% of the width of the shielding tape.

[0012] Preferably, the set overlapping width is 5%-50% of the width of the shielding tape.

[0013] The width of the overlapping portion can be 1%-95% of the width of the shielding tape. Preferably, the overlapping width is set to 5%-50% of the width of the shielding tape, so that the shielding layer wraps the insulating layer and the conductive core more completely, and most of the conductive core is wrapped by the shielding tape, further improving the electromagnetic shielding performance.

[0014] Furthermore, the shielding tape is made of at least one of aluminum foil and copper foil.

[0015] Aluminum foil and copper foil are relatively lightweight, highly ductile, and provide excellent electromagnetic shielding capabilities, while also having low material and processing costs. Alternatively, the shielding layer may be a combination of one or more of a shielding metal or composite material thereof, a shielding plastic or rubber, or a shielding textile.

[0016] Furthermore, the thickness of the shielding layer is 0.001 mm-27 mm.

[0017] Using a shielding layer with a thickness ranging from 0.001mm to 27mm ensures effective shielding and prevents the flat-belt conductive wire from having an excessively large bending radius that could affect its installation. Furthermore, the shielding layer covers at least 7.8% of the surface area of ​​the insulating layer. Furthermore, the thickness of the gap between the insulating layer and the shielding layer is no greater than 157mm. Furthermore, the thickness of the gap between the insulating layer and the shielding layer is no greater than 157mm.

[0018] Furthermore, the insulating layer is wrapped around the conductive core by a combination of one or more of an extrusion process, an injection molding process, a spraying process, a dipping process, a slush molding process, an electrophoresis process, a winding process or a braiding process.

[0019] Furthermore, the protective layer wraps the shielding layer through one or more combinations of extrusion, injection molding, spraying, dipping, slush molding, electrophoresis, braiding or winding processes.

[0020] Furthermore, the conductive core is made of one or more of aluminum, aluminum alloy, copper, copper alloy, silver, and a combination of silver alloys.

[0021] Optionally, the conductive core is an aluminum flat strip, which has the advantages of light weight, stable electrical connection performance and low cost.

[0022] Furthermore, the conductive core is made of carbon or a carbon-based compound, such as graphite, carbon nanotubes, graphene, etc., which also have excellent electrical conductivity.

[0023] Furthermore, the insulating layer is made of a material selected from the group consisting of polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, cross-linked polyolefin, synthetic rubber, polyurethane elastomer, cross-linked polyethylene, and a combination of one or more of polyethylene.

[0024] As an optional solution, the number of the conductive core is one.

[0025] As an optional solution, the number of the conductive cores is at least two, at least one conductive core is wrapped with the insulating layer, and at least one shielding layer wraps at least one insulating layer.

[0026] Specifically, the flat-belt conductive wire is a multi-core flat-belt conductive wire, including a protective layer, an insulating layer and at least two conductive cores; the protective layer, the insulating layer and the conductive cores are all arranged in a flat shape; at least one conductive core is wrapped with the insulating layer, and the protective layer is located at the outermost layer of the flat-belt conductive wire.

[0027] The flat-belt conductive wire includes at least two conductive cores, that is, a flat-belt conductive wire integrates multiple conductive cores, thereby realizing independent electrical connection of multiple paths. By fixing a flat-belt conductive wire provided by the present invention, the setting of multiple paths can be completed. On the one hand, it can avoid the problem of poor connection stability when multiple independent flat-belt wire harnesses are formed into multiple paths, and avoid the risk of falling off after loading; on the other hand, multiple conductive cores are integrated into one conductive wire, the structure is regular and compact, and it takes up less installation space; on the other hand, it saves the process of assembling multiple flat-belt wire harnesses, the installation efficiency is high, and it is conducive to intelligent manufacturing. Moreover, the flat-belt conductive wire can not only realize independent electrical connection of multiple paths, but also has good electromagnetic shielding performance.

[0028] As an optional solution, the at least two conductive cores are arranged in sequence along the width direction of the conductive core.

[0029] As an optional solution, along the thickness direction of the conductive core, the at least two conductive cores are stacked.

[0030] As an optional solution, a plurality of the conductive cores are provided in both the width direction of the conductive core and the thickness direction of the conductive core.

[0031] Furthermore, in the same stacking direction, the at least two conductive cores are arranged opposite to each other.

[0032] Such a flat-belt conductive wire has a regular structure and is easy to process and manufacture.

[0033] The flat-belt conductive wire can not only realize multi-channel independent electrical connection, but also has good electromagnetic shielding performance.

[0034] Furthermore, the multiple insulating layers are integrally formed, which can make the flat-belt conductive wire more stable and facilitate the arrangement of the protective layer.

[0035] The present invention provides a flat belt type wiring harness, comprising a terminal and the above flat belt type conductive wire body, wherein the terminal is connected to the end of the conductive core body.

[0036] It should be understood that both the foregoing general description and the following detailed description are intended to be illustrative and explanatory only and are not restrictive of the scope of protection of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the specific embodiments of the present invention, the following will briefly introduce the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0038] FIG1 is a schematic structural diagram of a first flat-belt conductive wire provided by the present invention;

[0039] FIG2 is a schematic structural diagram of a second flat-belt conductive wire provided by the present invention;

[0040] FIG3 is a schematic structural diagram of a third flat-belt conductive wire provided by the present invention;

[0041] FIG4 is a schematic structural diagram of a fourth flat-belt conductive wire provided by the present invention;

[0042] FIG5 is a schematic structural diagram of a fifth flat-belt conductive wire provided by the present invention;

[0043] FIG6 is a schematic structural diagram of a sixth flat-belt conductive wire provided by the present invention;

[0044] FIG7 is a schematic structural diagram of a seventh flat-belt conductive wire provided by the present invention;

[0045] FIG8 is a schematic structural diagram of an eighth flat-belt conductive wire provided by the present invention;

[0046] FIG9 is a schematic structural diagram of a ninth flat-belt conductive wire provided by the present invention;

[0047] FIG10 is a schematic structural diagram of a tenth flat ribbon type conductive wire provided by the present invention;

[0048] FIG11 is a schematic structural diagram of an eleventh flat-belt conductive wire provided by the present invention;

[0049] FIG12 is a cross-sectional view of a shielding layer provided by an embodiment of the present invention;

[0050] FIG13 is a cross-sectional view of another shielding layer provided by an embodiment of the present invention.

[0051] Description of main component symbols:

[0052] 10-protective layer; 20-insulating layer; 30-conductive core; 40-shielding layer; 41-shielding tape; 42-overlapping portion; 411-aluminum foil tape; 412-copper foil tape. DETAILED DESCRIPTION

[0053] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0054] The components of the embodiments of the present invention generally described and shown in the drawings herein may be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of the invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the invention.

[0055] Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative work shall fall within the scope of protection of the present invention.

[0056] It should be noted that the flat-belt conductive wire provided in the embodiment of the present invention can be used in, but not limited to, vehicles, and can also be used in other devices that require electrical connections.

[0057] It should be noted that, in the embodiment of the present invention, “a plurality of conductive cores 30 ”, namely “at least two conductive cores 30 ”, means that the number of the conductive cores 30 is two or more and includes two.

[0058] As shown in Figures 1, 3, 5, 6 to 11, the present invention provides a flat-belt conductive wire, comprising: a conductive core 30, an insulating layer 20, and a shielding layer 40; the insulating layer 20 wraps the conductive core 30, and the shielding layer 40 is disposed outside the insulating layer 20. The flat-belt conductive core provided in this embodiment, by providing the shielding layer 40, has good electromagnetic shielding function, strong anti-electromagnetic interference capability, and low installation space requirements. It can be widely used in situations requiring high signal transmission stability. It also avoids the problems of large space occupation and high cost caused by the use of large square circular shielded wires with shielding functions, thereby improving the space requirements for wiring harness layout in the entire vehicle.

[0059] It should be noted that the length and width of the insulating layer 20 , as well as the length and width of the shielding layer 40 , can be set according to the length and width of the conductive core 30 .

[0060] Among them, the shielding layer 40 is arranged outside the insulating layer 20, thereby wrapping the insulating layer 20, and then wrapping the conductive core 30. The shielding layer 40 and the insulating layer 20 can be arranged closely together, and a gap is also allowed between the shielding layer 40 and the insulating layer 20. The relationship between the thickness of the gap between the shielding layer and the insulating layer (that is, the vertical distance from a point on the insulating layer to the shielding layer tape) and the interference released by the flat-belt conductive wire is shown in the following Table 1:

[0061] Table 1

[0062]

[0063] According to the test results shown in Table 1, when the distance between the shielding layer 40 and the insulating layer 20 (the thickness of the gap between the shielding layer and the insulating layer) is 157 mm, the interference released by the flat-belt conductive wire is 19.6 dB, which is less than 20 dB; when the distance between the shielding layer 40 and the insulating layer 20 is greater than 157 mm, the interference released by the flat-belt conductive wire is greater than 20 dB; according to the introduction to shielding effectiveness in the relevant standards, the released interference is less than 20 dB to meet the shielding level requirements. Therefore, the gap should not be greater than 157 mm. Such a setting can ensure the shielding effect.

[0064] Specifically, the flat-belt conductive wire further includes a protective layer 10, which wraps the shielding layer 40. In this embodiment, the protective layer 10 is disposed outside the shielding layer 40 to protect the shielding layer and extend the service life of the flat-belt conductive wire.

[0065] The protective layer 10 , the insulating layer 20 and the conductive core 30 may all be arranged in a flat shape.

[0066] The material of the insulating layer 20 can be polycarbonate, polyvinyl chloride (PVC), polyurethane (PUR), nylon (PA), polypropylene (PP), TPU, silicone rubber (SIR), XLPO, TPU, TPV, PE, polysulfone, polytetrafluoroethylene, polyethylene, polyphenylene oxide, polyester, PPS, phenolic resin, urea formaldehyde, DAP, TPE, XPE, XLPE, PFE, ETFE, TPR, TPE-O, perfluoroalkoxyalkane, TPE-S, PBT, EZM, styrene-acrylonitrile copolymer, ABS, polymethacrylate, EVA, polyphenylene sulfide, polystyrene, PBT, polyoxymethylene resin, natural rubber, styrene-butadiene rubber, nitrile rubber, butadiene rubber, isoprene rubber, ethylene-propylene rubber, chloroprene rubber, butyl rubber, fluororubber, polyurethane rubber, polyacrylate rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, chlorinated polyethylene rubber, chlorosulfur rubber, butadiene rubber, hydrogenated nitrile rubber, polysulfide rubber, etc.

[0067] Preferably, the material of the insulating layer 20 is a combination of one or more of polyvinyl chloride (PVC), polyurethane (PUR), nylon (PA), polypropylene (PP), silicone rubber (SIR), cross-linked polyolefin (XLPO), synthetic rubber, polyurethane elastomer, cross-linked polyethylene (XLPE), polyethylene (PE) (for example, a combination of polypropylene and polyethylene; a combination of polyvinyl chloride and polyethylene, etc.).

[0068] The material of the conductive core 30 can be: one or more combinations of nickel, cadmium, zirconium, chromium, manganese, aluminum, tin, titanium, zinc, cobalt, gold, silver or their alloys; or, the material of the conductive core can also be: aluminum-magnesium alloy, aluminum-lithium alloy, aluminum-manganese alloy, aluminum-zinc alloy or aluminum-silicon alloy; or, the material of the conductive core contains carbon or carbon-based compounds, such as graphite, graphene, carbon nanotubes and other materials; optionally, the material of the conductive core can be a combination of one or more of aluminum, aluminum alloy, copper, copper alloy, silver and silver alloy.

[0069] Based on the above embodiments, a shielding layer 40 can be formed by weaving a metal with a shielding effect (for example, copper or aluminum, etc.), or a shielding layer 40 can be formed by mixing a metal and a plastic with a shielding effect (for example, a metal layer such as copper or aluminum is plated on the outside of a plastic such as ABS) and weaving together. Alternatively, the shielding layer 40 is a plate structure; or the shielding layer 40 is a cross-overlapping structure of multiple shielding tapes; or the shielding layer 40 is a layered structure formed by metal and plastic, such as PET aluminum foil.

[0070] The shielding layer can be formed by using one or more combinations of metals with shielding properties and their composite materials, plastics with shielding properties or rubbers with shielding properties (that is, in the process of producing plastics or rubbers, metal materials such as copper or aluminum are added to the raw materials, and materials such as graphene can also be added) or textiles with shielding properties (the structure of the textile contains parts made of metal materials with shielding properties).

[0071] Optionally, as shown in FIG. 12 and FIG. 13 , in this embodiment, the shielding layer 40 includes a shielding tape 41 , which is wrapped around the outside of the insulating layer 20 . This arrangement makes the shielding layer 40 easy to process.

[0072] Among them, the shielding tape 41 can be wound in a variety of ways, as long as the winding method can wrap the insulating layer 20, it can be adopted. For example: along the length direction of the insulating layer 20, multiple turns of independent shielding tape 41 are set. It can be understood that the shielding tape 41 is divided into multiple sections. A section of shielding tape 41 is wound around the outer wall of the insulating layer 20, and then another section of shielding tape 41 is wound around its adjacent position (optionally, the shielding tape 41 of the latter circle has an overlapping part with the shielding tape 41 of the previous circle, so that the shielding layer 40 has a better wrapping effect on the insulating layer 20, thereby making the electromagnetic shielding effect of the flat-belt conductive wire better). Repeat the above work until the entire conductive core 30 wrapped with the insulating layer 20 is wrapped.

[0073] As an optional solution, as shown in Figure 12, shielding tape 41 is spirally wound around the insulating layer 20 with a set overlapping width. That is, the shielding tape 41 is tightly wound around the insulating layer 20. Specifically, during the winding process, a portion of the subsequent circle of shielding tape 41 covers the previous circle of shielding tape 41, and an overlapping portion 42 exists between the two. The width of the overlapping portion 42 is the overlapping width. A whole section of shielding tape 41 can be wound around the insulating layer 20, and the section of shielding tape 41 is uninterrupted during the winding process. This winding method is simple and easy to operate and process. It can more completely wrap the insulating layer 20 and the conductive core 30, leaving no exposed parts, and has a better shielding effect.

[0074] The overlap width, i.e., the width of the overlap portion 42, can be set to 1%-95% of the width of the shielding tape 41. Table 2 shows the shielding effectiveness of the flat-belt conductive wire when the overlap width is set to 0%-5% of the width of the shielding tape 41; Table 3 shows the shielding effectiveness of the flat-belt conductive wire when the overlap width is set to 0%-100% of the width of the shielding tape 41. The details are as follows:

[0075] Table 2

[0076]

[0077] Table 3

[0078]

[0079]

[0080] According to the test results shown in Tables 2 and 3, when the overlapping width is set to the width of the shielding tape 41 greater than 1%, the shielding effectiveness is greater than 20 dB, meeting the requirements of the relevant standards; when it is greater than 95%, the shielding effectiveness is almost unchanged. In order to save the use of shielding tape, the range is locked to 1%-95%. It can be seen from the data that when the overlapping width is set to the width of the shielding tape 41 at 5%, the shielding effectiveness is significantly improved. When it reaches 50%, the shielding effectiveness can reach 72.1 dB. When it exceeds 50%, the test data does not change significantly. In order to save the use of shielding tape, it is recommended that the overlapping width, i.e., the width of the overlapping portion 42, be preferably set to 5%-50% of the width of the shielding tape 41.

[0081] As shown in FIG12 , the shielding tape 41 may be made of a material having electromagnetic shielding function, such as PET aluminum foil.

[0082] As an optional solution, the material of the shielding tape 41 includes at least one of aluminum foil or copper foil, that is, the shielding tape 41 can be an aluminum foil tape, which is wrapped around the insulating layer 20 to form an aluminum foil shielding layer; the shielding tape 41 can also be a copper foil tape, which is wrapped around the insulating layer 20 to form a copper foil shielding layer; at this time, if the shielding tape 41 adopts a dense winding method, a whole section of aluminum foil tape or copper foil tape can be used to wrap the insulating layer 20; or, the shielding tape 41 includes both aluminum foil tape and copper foil tape, for example: as shown in Figure 13, the shielding tape 41 is spliced ​​by a section of aluminum foil tape 411 and a section of copper foil tape 412 to form a spliced ​​or overlapping structure, and the aluminum foil tape 411 and the copper foil tape 412 have overlapping parts at the splicing or overlapping position. At this time, if the shielding tape 41 is tightly wound, the splicing or overlapping structure can be used to wrap the insulating layer 20; for example: there are multiple shielding layers 40, and the multiple shielding layers 40 are arranged in sequence from the inside to the outside, that is, the latter shielding layer 40 wraps the previous shielding layer 40, wherein there is at least one shielding layer 40 that is an aluminum foil shielding layer formed by winding an aluminum foil tape, and the other shielding layer 40 is a copper foil shielding layer formed by winding a copper foil tape; or, an aluminum foil shielding layer and a copper foil shielding layer are arranged alternately, etc.

[0083] In this embodiment, aluminum foil and copper foil are generally lightweight, highly ductile, and provide excellent electromagnetic shielding capabilities, while also offering low material and processing costs. Aluminum foil is lighter than copper foil, and copper foil offers superior shielding capabilities, allowing for selection based on specific needs. However, the scope of protection of this invention is not limited to copper or aluminum foil; other materials with shielding properties are also contemplated.

[0084] Based on the above embodiment, the thickness of the shielding layer 40 can be set according to specific circumstances. For example, the effect of the thickness of the shielding layer on EMI (electromagnetic interference), the effect of the thickness of the shielding layer on FRI (radio frequency interference), and the effect of the thickness of the shielding layer on the bending radius of the flat-belt conductive wire are comprehensively considered to select a suitable thickness of the shielding layer. The relationship between the thickness of the shielding layer and EMI, the relationship between the thickness of the shielding layer and FRI, and the relationship between the thickness of the shielding layer and the increase in the bending radius of the flat-belt conductive wire are shown in Table 4 below:

[0085] Table 4

[0086]

[0087] According to the test results shown in Table 4, it can be seen that when the thickness of the shielding layer 40 is between 0.001mm and 27mm, the shielding effect of the flat-belt conductive wire, i.e., anti-electromagnetic interference (EMI) and anti-radio frequency interference (FRI), will increase with increasing thickness, but when the thickness of the shielding layer 40 exceeds 27mm, the shielding ability of the flat-belt conductive wire changes little and there is no obvious improvement; when the thickness of the shielding layer 40 is between 0.001mm and 27mm, the increase in the turning radius of the flat-belt conductive wire will increase with increasing thickness, but when the thickness of the shielding layer 40 exceeds 27mm, the increase in the turning radius of the flat-belt conductive wire exceeds 200mm, which is not conducive to actual processing. Therefore, the preferred thickness of the shielding layer is 0.001mm-27mm.

[0088] Based on the above embodiments, the amount of surface area covered by the shielding layer on the insulating layer can be set according to specific needs. Table 5 shows the shielding effectiveness of the flat-belt conductive wire when the shielding layer covers 0.8%-7.8% of the surface area of ​​the insulating layer. Table 6 shows the shielding effectiveness of the flat-belt conductive wire when the shielding layer covers 0.8%-100% of the surface area of ​​the insulating layer.

[0089] Table 5

[0090]

[0091] Table 6

[0092]

[0093]

[0094] According to the test results shown in Tables 5 and 6, it can be seen that when the shielding layer covers less than 7.8% of the surface area of ​​the insulating layer, the shielding effectiveness of the flat-belt conductive wire is less than 20dB, which does not meet the relevant usage requirements. When it is greater than or equal to 7.8%, it has relatively good shielding effectiveness. Therefore, the shielding layer covers at least 7.8% of the surface area of ​​the insulating layer.

[0095] In addition to any of the above technical solutions, the insulating layer 20 can further be made of materials such as plastic and rubber. The insulating layer 20 can be formed by extrusion, injection molding, spraying, dipping, slush molding, electrophoresis, winding, or braiding, or a combination thereof. The insulating layer 20 formed by the above processes has good strength, good stability, and high production efficiency.

[0096] Winding processes include: insulating tape strips are wrapped around the conductor in multiple layers to form a staggered and tight structure, and the viscosity of the insulating tape material is used to form an insulating and closed environment.

[0097] Weaving process, for example: multiple layers of insulating tape material are braided and wrapped around the outside of the conductor to form a staggered and tight structure, and the viscosity of the insulating tape material is used to form an insulating and closed environment.

[0098] Extrusion molding refers to a processing method in which the material passes through the action between the extruder barrel and the screw, is heated and plasticized, and is pushed forward by the screw, continuously passing through the extruder head and the corresponding shape of the mold to form various cross-section products or semi-finished products.

[0099] Injection molding refers to the process in which an injection molding machine pressurizes, injects, cools, and separates molten raw materials to produce finished parts of a certain shape in a mold of corresponding shape.

[0100] Spraying molding is a molding process in which the material is sprayed directly onto the surface of the object to be processed or into the mold cavity, and then solidified into shape.

[0101] Dip coating is a plastic coating process that can be categorized into powder and liquid based on the raw materials used. Powder coating is commonly used for coating metal surfaces and is characterized by its strong, durable powder coating. Liquid dipping processes mostly utilize hot dip coatings. Thermoplastic coatings soften upon heat and solidify upon cooling. This process is primarily a physical melt-plasticization process, making processing and production relatively simple. Liquid dip coatings are thicker and more flexible, allowing them to be removed from the mold and used as a standalone, protective product.

[0102] Slush molding, also known as gel coating, is an important method for manufacturing hollow, flexible products from plastic pastes. The advantages of slush molding are low equipment costs, high production speeds, and simple process control, but the accuracy of product thickness and weight is relatively poor.

[0103] Electrophoresis molding is a process that uses a water-soluble organic coating with an electric charge, which is evenly dissolved in a solution. The metal material and the workpiece to be processed are used as the positive or negative electrode, and an electric current is passed through the organic coating to adhere to the workpiece to be processed. The finished product is obtained through drying and curing.

[0104] The protective layer 10 can be made of an insulating material, such as plastic or rubber. While providing protection, the protective layer 10 also provides insulation, thereby improving the stability of the flat-belt conductive wire. The protective layer 10 can be formed by one or a combination of extrusion, injection molding, spraying, dipping, slush molding, electrophoresis, winding, or braiding. The protective layer 10 formed using these processes exhibits superior strength, stability, and production efficiency.

[0105] The protective layer 10 can have various structural forms. For example, along the length direction of the conductive core 30, the protective layer 10 includes a plurality of protective layer segments arranged at intervals. Optionally, the protective layer 10 is arranged as a whole outside the insulating layer 20 for easy processing.

[0106] It should be noted that at least one of the insulating layer 20 and the protective layer 10 can be formed by one or more combinations of extrusion molding, injection molding, spray molding, dipping molding, slush molding, electrophoresis molding, winding molding or weaving molding. The insulating layer 20 or the protective layer 10 formed by the above-mentioned process has good strength, good stability and high production efficiency.

[0107] The number of conductive cores can be one or more, as described below with an example:

[0108] First example:

[0109] Based on any of the above embodiments, the flat-belt conductive wire provided in this embodiment has one conductive core. Specifically, as shown in FIG1 , the flat-belt conductive wire provided in this embodiment includes: a conductive core 30, an insulating layer 20, a shielding layer 40, and a protective layer 10. There is one conductive core 30, and there is one insulating layer 20. The insulating layer 20 wraps around the conductive core 30, the shielding layer 40 wraps around the insulating layer 20, and the protective layer 10 wraps around the shielding layer 40. The protective layer 10, the insulating layer 20, and the conductive core 30 can all be flat.

[0110] The flat-belt conductive wire provided in this embodiment has good electromagnetic shielding function and strong anti-electromagnetic interference ability after the shielding layer 40 is provided, and has low requirements for installation space. It can be widely used in occasions with high requirements for signal transmission stability. At the same time, it can avoid the problems of large space occupation and high cost caused by the use of large-square shielded wires with shielding function, and improves the space requirements of the entire vehicle for wiring harness layout.

[0111] Second example:

[0112] Based on any of the above embodiments, the number of conductive cores in the flat-belt conductive wire provided by this embodiment is at least two. Specifically, as shown in Figures 2 to 11, the flat-belt conductive wire provided by this embodiment includes a protective layer 10, an insulating layer 20, a shielding layer 40 and at least two conductive cores 30; the protective layer 10, the insulating layer 20 and the conductive core 30 are all arranged in a flat shape; at least one conductive core 30 is wrapped with an insulating layer 20, at least one shielding layer 40 wraps at least one insulating layer 20, and the protective layer 10 is arranged on the outermost layer of the flat-belt conductive wire.

[0113] In this embodiment, the flat-belt conductive wire includes at least two conductive cores 30. In other words, a single flat-belt conductive wire integrates multiple conductive cores 30, with multiple pathways independently electrically connected. By securing a single flat-belt conductive wire provided by this embodiment, multiple pathways can be configured. This avoids the problem of poor connection stability that can occur when connecting multiple independent flat-belt wiring harnesses to form multiple pathways, thereby reducing the risk of them falling off after installation. Furthermore, the integration of multiple conductive cores 30 into a single conductive wire creates a neat, compact structure that takes up minimal installation space. Furthermore, this eliminates the need to assemble multiple flat-belt wiring harnesses, facilitating installation and increasing efficiency, thus facilitating intelligent manufacturing. Furthermore, a shielding layer 40 is provided outside the insulating layer 20. This shielding layer 40 provides the flat-belt conductive wire with excellent electromagnetic shielding, strong resistance to electromagnetic interference, and minimal installation space requirements. This allows for widespread application in applications requiring high signal transmission stability. It also avoids the space requirements and high costs associated with using large-square shielded wire, thereby improving the overall vehicle wiring harness layout space requirements. The flat-belt conductive wire provided in this embodiment can not only realize multi-channel setting, but also has electromagnetic shielding function.

[0114] The number of the at least two conductive cores 30 may be two, three, four, or five, etc. The number of the conductive cores 30 may be set as required.

[0115] Among them, as shown in FIG3 , only one conductive core 30 or part of the conductive cores 30 can be wrapped with an insulating layer 20; while the other conductive cores 30 without the insulating layer 20 are directly in contact with the protective layer 10, and the protective layer 10 can serve as the insulating layer of the conductive core 30; optionally, as shown in FIG5 , each conductive core 30 is wrapped with an insulating layer 20, which has better insulation performance and is convenient for processing. Optionally, as shown in FIG4 to FIG11 , each conductive core 30 is wrapped with an insulating layer 20, which has better insulation performance and is convenient for processing.

[0116] The specifications of the multiple conductive cores 30 may be different; some of the conductive cores 30 may have the same specifications, while some of the conductive cores 30 may have different specifications; optionally, the specifications of the multiple conductive cores 30 are the same, that is, the size and structure of the multiple conductive cores 30 are the same, which is convenient for processing.

[0117] The multiple insulating layers 20 can be arranged in various ways. For example, each conductive core 30 can be independently subjected to extrusion molding, injection molding, spray molding, dipping molding, slush molding, electrophoresis molding, winding molding or braiding molding to form corresponding independent insulating layers 20. Optionally, a unified extrusion molding, injection molding, spray molding, dipping molding, slush molding, electrophoresis molding, winding molding or braiding molding can be performed outside the multiple conductive cores 30 to make the multiple insulating layers 20 a whole, that is, the multiple insulating layers 20 are formed as one piece. This arrangement can make the flat-belt conductive wire more stable and facilitate the arrangement of the protective layer 10.

[0118] Based on the above embodiment, the multiple conductive cores 30 can be arranged in various ways. For example, along the width direction of the conductive core 30, the multiple conductive cores 30 are arranged in sequence, which can also be understood as the multiple conductive cores 30 are arranged left and right.

[0119] Among them, in the thickness direction of the conductive core 30, the positions of multiple conductive cores 30 can be different, for example: the number of conductive cores 30 is two, and one conductive core 30 is completely staggered with the other conductive core 30; or, as shown in Figure 2, one conductive core 30 and another conductive core 30 are partially overlapped; or, in the thickness direction of the conductive core 30, the positions of some conductive cores 30 can be set to the same, and the positions of some conductive cores 30 can be set to different, for example: the number of conductive cores 30 is three, among which the positions of two conductive cores 30 are the same, and the position of the other conductive core 30 is different from the positions of the above two conductive cores 30.

[0120] As an optional solution, as shown in Figures 3 and 4, multiple conductive cores 30 are arranged opposite each other in the width direction of the conductive core 30, that is, in the thickness direction of the conductive core 30, the positions of the multiple conductive cores 30 are consistent. It can also be understood that the side perpendicular to the width direction of the conductive core is the first side, and the first sides of two adjacent conductive cores are arranged face to face. Such a flat-belt conductive wire has a regular structure and is convenient for processing and manufacturing.

[0121] For another example, another arrangement of the multiple conductive cores 30 may be: at least two conductive cores 30 are stacked along the thickness direction of the conductive core 30 , which can also be understood as multiple conductive cores 30 being arranged up and down.

[0122] Among them, in the width direction of the conductive core 30, the positions of multiple conductive cores 30 can be set differently, for example: the number of conductive cores 30 is two, and one conductive core 30 is completely staggered with the other conductive core 30; or, as shown in Figure 7, one conductive core 30 and another conductive core 30 are partially overlapped; or, in the width direction of the conductive core 30, the positions of some conductive cores 30 are set the same, and the positions of some conductive cores 30 are set differently, for example: the number of conductive cores 30 is three, among which the positions of two conductive cores 30 are the same, and the position of the other conductive core 30 is different from the positions of the above two conductive cores 30.

[0123] As an optional solution, as shown in Figures 8 to 10, multiple conductive cores 30 are arranged opposite each other in the thickness direction of the conductive core 30, that is, in the width direction of the conductive core 30, the positions of the multiple conductive cores 30 are consistent. It can also be understood that the side perpendicular to the thickness direction of the conductive core is the second side, and the second sides of two adjacent conductive cores are arranged face to face. Such a flat-belt conductive wire has a regular structure and is convenient for processing and manufacturing.

[0124] For example, another arrangement of the multiple conductive cores 30 can be: as shown in Figure 11, multiple conductive cores 30 are arranged in the width direction of the conductive core 30 and in the thickness direction of the conductive core 30, that is, the multiple conductive cores 30 are stacked both in the thickness direction and in the width direction. The arrangement of the multiple conductive cores 30 provided in this embodiment is applicable to the case when the number of the conductive cores 30 is at least three.

[0125] As shown in Figures 5, 10, and 11, when multiple insulating layers 20 are provided independently of one another, one shielding layer 40 wraps around at least one insulating layer 20. For example, the number of shielding layers 40 is the same as the number of insulating layers 20, and the multiple shielding layers 40 are wrapped around the multiple insulating layers 20 in a one-to-one correspondence; alternatively, the number of shielding layers 40 is greater than one but less than the number of insulating layers 20, and at least one shielding layer 40 wraps around multiple insulating layers 20; alternatively, one shielding layer 40 simultaneously wraps around multiple insulating layers 20. When multiple insulating layers 20 are integrally formed, the shielding layer 40 can be directly wrapped around the outer walls of the multiple insulating layers 20.

[0126] Regardless of whether the multiple insulating layers 20 are independently provided or formed integrally, at least one shielding layer 40 is wrapped around each insulating layer 20. That is, the number of shielding layers 40 can be one, two, three, or four. The multiple shielding layers 40 can be wrapped around the insulating layer 20 layer by layer from the inside out.

[0127] It should be noted that the flat-belt conductive wire provided by the embodiment of the present invention may encounter bending in actual applications. The flat-belt conductive wire provided by the embodiment of the present invention can be bent in the same plane. It can be understood that the bending portion in the flat-belt conductive wire and the wire bodies on both sides of the bending portion are in the same plane; or, the wire body on one side of the bending portion is located in one plane, and the wire body on the other side of the bending portion is located in another plane. For example: the flat-belt conductive wire forms an acute angle, an obtuse angle or a right angle after bending.

[0128] In practical applications, the flat-belt conductive wire provided by the embodiment of the present invention may not be grounded, that is, the shielding layer may not be grounded, or the shielding layer in the flat-belt conductive wire provided by the embodiment of the present invention may be at least partially grounded. The effects of the two usage scenarios on the ability to resist magnetic field interference, the ability to resist radio frequency interference, the ability to electromagnetic interference, and the safety capability are compared as shown in Table 7 below:

[0129] Table 7

[0130]

[0131] Based on any of the above embodiments, the present invention further provides a flat-belt wiring harness, comprising a terminal and a flat-belt conductive wire of any of the above technical solutions, wherein the terminal is connected to an end of the flat-belt conductive wire.

[0132] The flat-belt type wiring harness provided in this embodiment has all the beneficial technical effects of the flat-belt type conductive wire body, and will not be described in detail here.

[0133] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art will understand that the technical solutions described in the aforementioned embodiments may still be modified, or some or all of the technical features therein may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention. In the description provided herein, a large number of specific details are described. However, it is understood that the embodiments of the present invention can be practiced without these specific details. In some instances, well-known methods, structures, and techniques are not shown in detail so as not to obscure the understanding of this description. In addition, those skilled in the art will understand that although some embodiments herein include certain features included in other embodiments but not other features, the combination of features of different embodiments is meant to be within the scope of the present invention and form different embodiments.

Claims

DEPCT 661. A flat conductive wire instrument consisting of: a conductive core body, an insulating layer, and a protective sheath, in which the insulating layer encloses the conductive core body, and the protective sheath is arranged outside the insulating layer.

2. A flat conductive wire instrument as described in claim 1, which is further composed of a protective layer enclosing the protective sheath.

3. A flat conductive wire instrument as described in claim 1, in which the protective sheath consists of a protective sheath strip which is wrapped to 4. Conductive flat wire objects under claim clause 3, where the shielding strip is twisted with a specified overlap width on the insulation layer.

5. Conductive flat wire objects under claim clause 4, where the specified overlap width is 1% to 95% of the width of the shielding strip.

6. Conductive flat wire objects under claim clause 5, where the specified overlap width is 5% to 50% of the width of the shielding strip. 7.

8. Conductive wire of the flat strip type under claim 1, where the shielding layer is made of one or more types selected from a group of shielding metals and composite materials of such types, shielding plastics, shielding rubbers, and shielding fibriks.

9. Conductive wire of the flat strip type under claim 1, where the shielding layer thickness is 0.001 mm to 27 mm.

10. Conductive wire of the flat strip type under claim 1, where the shielding layer covers at least 7.8% of the surface area of ​​the shielding layer.

10. Conductive wire materials of the flat strip type as per claim 1, where the thickness of the gap between the insulation and sheath layers is not more than 157 mm.

11. Conductive wire materials of the flat strip type as per claim 1, where the insulation layer encloses the conductive core body by one or more methods selected from a group comprising extrusion, injection molding, spraying, dip molding, slush molding, electrophoresis, winding, and weaving processes. 12.

13. Conductive wires of the flat strip type under Reputation Clause 1, where the conductive core body material is one or more selected from the group of processes comprising extrusion, injection molding, spraying, dip molding, slush molding, electrophoresis, weaving and winding.

14. Conductive wires of the flat strip type under Reputation Clause 1, where the conductive core body material is one or more selected from the group of processes comprising aluminum, aluminum alloys, copper, copper alloys, silver, and silver alloys.

15. Conductive wires of the flat strip type under Reputation Clause 1, where the conductive core body material is carbon or carbon-based compounds.

16. Conductive wire of the flat strip type under Reputation 1, in which the insulation material is one or more types selected from the group comprising polyvinyl chloride, polyurethane, nylon, polypropylene, silicone rubber, crosslinked polyolefin, synthetic rubber, polyurethane elastomer, crosslinked polyethylene, and polyethylene.

17. Conductive wire of the flat strip type under Reputation 1, in which the number of conductive core sections is one. A flat cable assembly under claim 1, in which the number of conductive core sections is at least two, at least one conductive core section is externally enclosed by an insulating layer, and at least one insulating layer is enclosed by at least one protective layer.

18. A flat cable assembly, which consists of terminals and conductive wires of the flat type under any of claims 1 to 17, in which the terminals are connected to the ends of the conductive core sections;

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